Fastening assembly and cushion having fastening assembly

ABSTRACT

A fastening assembly and a cushion having the fastening assembly are provided. The fastening assembly essentially includes a first band, a second band, and a third band. The first band has a first surface protrudingly provided with a plurality of hooks, and a second surface. The second band is made of a sponge material and is provided lengthwise with a central concave portion for receiving the first band which is placed with the second surface facing the second band. The central concave portion is formed bilaterally with a pair of sidewalls, wherein the depth of the central concave portion is not less than the thickness of the first band plus the hooks. The third band is bonded to the bottom of the second band, wherein a magnetic material is placed between the second band and the third band.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a fastening assembly and, more particularly, to a fastening assembly co-molded with a foam article.

2. Description of Related Art

The conventional hook-and-loop fastener was invented by George de Mestral, a Swiss engineer, under the inspiration of burrs. The hook-and-loop fastener consists of a hook side woven with tiny hooks and a loop side covered with even smaller and finer loop-like fastening structures. When the hook side and the loop side are pressed together, the hooks on the hook side are caught in the loop-like fastening structures on the loop side so that the two sides are fastened together.

In recent years, the hook-and-loop fastener, which is easily assembled and detached, is often coupled and used with other articles. When a hook-and-loop fastener is applied to a foam article such as a seat cushion, a buffer pad, and so on, the hook-and-loop fastener is bonded to the foam article with the hooks of the hook-and-loop fastener facing outward so as to fasten with another article having a corresponding loop side. Typically, a seat cushion with a hook-and-loop fastener is manufactured by placing the hook-and-loop fastener at a predetermined location in a mold and introducing a foam material into the mold. The foam material is co-molded with the hook-and-loop fastener and, when completely set, takes on the shape defined by the mold.

However, while the foam material expands, the expanding foam material tends to cover the hooks of the hook-and-loop fastener so that, after the foaming process is completed, the hooks of the hook-and-loop fastener of the final product cannot fasten with corresponding fastening structures. In other words, the final product is defective and results in waste of production cost. To overcome the aforesaid drawback, it was disclosed in U.S. Pat. No. 5,061,540 to equip the hook-and-loop fastener with flexible sealing portions for preventing the foam material from entering in between the hooks during the foaming process. Nevertheless, the hook-and-loop fastener protected by the above-cited patent must be used with a special mold. If the hook-and-loop fastener is placed merely on a planar surface of an ordinary mold without the dedicated trough for receiving the hook-and-loop fastener, the sealing portions provide no protection to the hooks.

BRIEF SUMMARY OF THE INVENTION

In order to remedy the aforesaid shortcoming of the prior art, the present invention provides a fastening assembly essentially comprising a first band, a second band, and a third band. The first band has a first surface and a second surface, wherein the first surface is protrudingly provided with a plurality of hooks. The second band is made of a sponge material and provided lengthwise with a central concave portion for receiving the first band therein such that the second surface of the first band faces the second band. The central concave portion is formed bilaterally with a pair of sidewalls, wherein the central concave portion has a depth not less than a combined thickness of the first band and the hooks. The third band is bonded to a bottom of the second band. A magnetic material is interposed between the second band and the third band for providing magnetic attraction to a magnet of a mold.

Therefore, a primary objective of the present invention is to provide a fastening assembly comprising a magnetic material which enables the fastening assembly to be readily secured in position to a mold by magnetic force during a foaming molding process and easily detached from the mold after the foaming molding process is completed.

Another objective of the present invention is to provide a fastening assembly comprising a first band flanked with sidewalls. The two sidewalls protect hooks of the fastening assembly from being invaded and damaged by a foam material during a foaming molding process. In addition, the sidewalls are made of a sponge material capable of absorbing an excess of the foam material so as to provide enhanced protection to the hooks.

The present invention also provides a cushion having a fastening assembly. The cushion comprises a foam cushion body and at least one said fastening assembly, wherein the foam cushion body and the fastening assembly are molded into one piece. The fastening assembly essentially comprises a first band, a second band, and a third band. The first band has a first surface and a second surface, wherein the first surface is protrudingly provided with a plurality of hooks. The second band is made of a sponge material and provided lengthwise with a central concave portion for receiving the first band therein such that the second surface of the first band faces the second band. The central concave portion is formed bilaterally with a pair of sidewalls, wherein the central concave portion has a depth not less than a combined thickness of the first band and the hooks. The depth is equal to or lightly greater than the combined thickness of the first band and the hooks so that the two sidewalls offer protection to the hooks during a foaming molding process. The third band is bonded to a bottom of the second band. A magnetic material is interposed between the second band and the third band for providing magnetic attraction to a magnet of a mold.

Hence, a further objective of the present invention is to provide a cushion having a fastening assembly, wherein the fastening assembly comprises a magnetic material which enables the fastening assembly to be readily secured in position to a mold by magnetic force during a foaming molding process and easily detached from the mold after the foaming molding process is completed.

Still another objective of the present invention is to provide a cushion having a fastening assembly, wherein the fastening assembly comprises a first band flanked with sidewalls. The two sidewalls protect hooks of the fastening assembly from being invaded and damaged by a foam material during a foaming molding process. In addition, the sidewalls are made of a sponge material capable of absorbing an excess of the foam material so as to provide enhanced protection to the hooks.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention as well as a preferred mode of use, further objectives and advantages thereof will be best understood by referring to the following detailed description of illustrative embodiments in conjunction with the accompanying drawings, wherein:

FIG. 1A is a perspective view of a fastening assembly according to a first preferred embodiment of the present invention;

FIG. 1B is a sectional view of the fastening assembly according to the first preferred embodiment of the present invention;

FIG. 1C is a sectional view of a fastening assembly according to another aspect of the first preferred embodiment of the present invention;

FIG. 1D is a sectional view of a fastening assembly according to yet another aspect of the first preferred embodiment of the present invention;

FIG. 1E is a sectional view of the fastening assembly according to the first preferred embodiment of the present invention when placed in a mold;

FIG. 2A is a perspective view of a cushion having a fastening assembly according to a second preferred embodiment of the present invention; and

FIG. 2B is an enlarged sectional view of the fastening assembly according to the second preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Disclosed herein are a fastening assembly and a cushion having the same. Since the physical principles involved in the present invention and the basic connection relations among related elements are well known to persons of ordinary skill in the art, a detailed description of such principles and relations is omitted herein. Besides, the drawings referred to in the following description are not drawn according to actual dimensions and need not be so because they are only intended to demonstrate features of the present invention schematically.

Please refer to FIG. 1A for a perspective view of a fastening assembly 1 according to a first preferred embodiment of the present invention and FIG. 1B for a sectional view of the fastening assembly 1 taken along line AA of FIG. 1A. The fastening assembly 1 essentially comprises a first band 11, a second band 12, and a third band 13. The first band 11 has a first surface 111 and a second surface 112, wherein the first surface 111 is protrudingly provided with a plurality of hooks 113. The second band 12 is made of a sponge material and provided lengthwise with a central concave portion 122. The central concave portion 122 is formed bilaterally with a pair of sidewalls 121. The first band 11 is placed in the central concave portion 122 with the second surface 112 facing the second band 12. The central concave portion 122 has a depth a not less than a combined thickness b of the first band 11 and the hooks 113.

The third band 13 is bonded to a bottom of the second band 12, with a magnetic material 14 disposed between the second band 12 and the third band 13. The third band 13 is configured for engaging with a foam material formed in a subsequent foaming molding process. The third band 13 supports and reinforces the fastening assembly 1, thereby preventing the bands from folding or deformation which might otherwise occur during the manufacturing process. Therefore, the third band 13 is preferably made of a tough material such as a non-woven material, a fibrous material, or even a plastic film.

Please refer to FIGS. 1C and 1D for further aspects of the fastening assembly according to the first preferred embodiment of the present invention. The magnetic material 14 is disposed between the second band 12 and the third band 13 for providing magnetic attraction to a magnet installed in a foaming mold. To increase the magnetic attraction, the magnetic material 14 is further provided in the fastening assembly 1 between the second surface 112 of the first band 11 and the second band 12. The magnetic material 14 can be provided in different ways. For example, the magnetic material 14 is substantially evenly coated on the second surface 112 of the first band 11, as shown in FIG. 1C. Alternatively, the magnetic material 14 is substantially evenly coated on a surface of the second band 12 that faces the first band 11, as shown in FIG. 1D. The magnetic material 14 is preferably in the form of powder to enable uniform magnetic attraction. Preferably, the magnetic material 14 is iron powder or powder of a ferrous alloy, on condition that the magnetic material 14 provides magnetic attraction to magnets.

Referring to FIG. 1E, a mold 3 is equipped with a magnet 31 at a predetermined location for accommodating the fastening assembly 1. When the fastening assembly 1 is placed in the mold 3, the magnetic material 14 is attracted magnetically to the magnet 31 of the mold 3, and thus the fastening assembly 1 is attracted and attached magnetically to the predetermined location of the mold 3 for accommodating the fastening assembly 1, so that the hooks 113 are enclosed between the mold 3 and the second band 12. Hence, during the foaming molding process, the sidewalls 121 of the second band 12 prevent the foam material from penetrating into the enclosure and damaging the hooks 113 of the fastening assembly 1. The number, shape, and location of the magnet 31 of the mold 3 are not limited as long as the fastening assembly 1 is magnetically attracted and securely attached to the magnet 31.

Besides the foregoing fastening assembly in the first preferred embodiment, the present invent also provides a cushion having a fastening assembly as a second preferred embodiment.

Referring to FIG. 2A for a perspective view of a cushion 2 having a fastening assembly 1 according to the second preferred embodiment of the present invention, the cushion 2 comprises a foam cushion body 20 and at least one said fastening assembly 1, wherein the foam cushion body 20 and the fastening assembly 1 are molded into one piece in a foaming molding process. Referring to FIG. 2B for an enlarged sectional view of the fastening assembly 1 of FIG. 2A, the fastening assembly 1 is identical to its counterpart in the first preferred embodiment in comprising essentially a first band 11, a second band 12, a third band 13, and a magnetic material 14. The above-cited components have substantially the same features and connection relations as their equivalents in the first preferred embodiment and therefore are not described repeatedly herein. In addition, the third band 13 of the fastening assembly 1 is engaged with the foam cushion body 20; or additionally, the pair of sidewalls 121 of the second band 12 are also engaged with the foam cushion body 20 to provide a more secure engaging effect.

Moreover, in a preferred mode of implementation, the foam cushion body 20 further has at least one groove 201 for receiving the fastening assembly 1 therein and thus allowing the cushion 2 to engage other articles (such as a leather bolster of a seat cushion or a backrest of a chair) having corresponding fastening structures.

The present invention is herein illustrated by reference to the preferred embodiments and the corresponding drawings to enable one skilled in the art to carry out the present invention. However, the embodiments are provided for illustrative purposes only but not intended to limit the scope of the present invention. In other words, changes or modifications which are made to the disclosed embodiments without departing from the spirit of the present invention should fall within the scope of the present invention, which is defined only by the appended claims. 

1. A fastening assembly, essentially comprising a first band having a first surface and a second surface, the first surface being protrudingly provided with a plurality of hooks, the fastening assembly being characterized by further comprising: a second band made of a sponge material and provided lengthwise with a central concave portion for receiving the first band therein such that the second surface of the first band faces the second band, wherein the central concave portion is formed bilaterally with a pair of sidewalls, and the central concave portion has a depth not less than a combined thickness of the first band and the hooks; and a third band bonded to a bottom of the second band, wherein a magnetic material is provided between the third band and the second band.
 2. The fastening assembly as claimed in claim 1, wherein the magnetic material is in a powder form.
 3. The fastening assembly as claimed in claim 2, wherein the magnetic material is iron powder magnetically attractable to a magnet.
 4. The fastening assembly as claimed in claim 2, wherein the magnetic material is powder of a ferrous alloy that is magnetically attractable to a magnet.
 5. The fastening assembly as claimed in claim 1, wherein the depth of the central concave portion of the second band is greater than the combined thickness of the first band and the hooks.
 6. The fastening assembly as claimed in claim 1, wherein the third band is made of a non-woven material.
 7. The fastening assembly as claimed in claim 1, wherein the third band is made of a fibrous material.
 8. The fastening assembly as claimed in claim 1, wherein the third band is made of a plastic film.
 9. The fastening assembly as claimed in claim 1, wherein the magnetic material is further provided between the second surface of the first band and the second band.
 10. The fastening assembly as claimed in claim 9, wherein the magnetic material is substantially evenly distributed on the second surface of the first band.
 11. The fastening assembly as claimed in claim 9, wherein the magnetic material is substantially evenly distributed on a surface of the second band that faces the first band.
 12. The fastening assembly as claimed in claims 9, wherein the magnetic material is in a powder form.
 13. The fastening assembly as claimed in claim 12, wherein the magnetic material is iron powder magnetically attractable to a magnet.
 14. The fastening assembly as claimed in claim 12, wherein the magnetic material is powder of a ferrous alloy that is magnetically attractable to a magnet.
 15. A cushion having a fastening assembly, the cushion comprising a foam cushion body and at least one said fastening assembly, the foam cushion body and the fastening assembly being molded into one piece, the cushion being characterized in that the fastening assembly comprising: a first band having a first surface and a second surface, the first surface being protrudingly provided with a plurality of hooks; a second band made of a sponge material and provided lengthwise with a central concave portion for receiving the first band therein such that the second surface of the first band faces the second band, wherein the central concave portion is formed bilaterally with a pair of sidewalls, and the central concave portion has a depth not less than a combined thickness of the first band and the hooks; and a third band bonded to a bottom of the second band, wherein a magnetic material is provided between the third band and the second band.
 16. The cushion having the fastening assembly as claimed in claim 15, wherein the foam cushion body engages with the third band of the fastening assembly.
 17. The cushion having the fastening assembly as claimed in claim 16, wherein the foam cushion body further engages with the pair of sidewalls of the second band of the fastening assembly.
 18. The cushion having the fastening assembly as claimed in claim 15, wherein the foam cushion body further has at least a groove for receiving the fastening assembly. 